Instead of replacing expensive equipment, TS (UK) used innovation funding to modernise it, “proving that you get very modern capabilities without a huge budget if you have an innovative mindset and the right support”.
Innovation grant funding
Reduction in energy consumption
Annual energy savings
New jobs created
Like many UK manufacturers, Middleton-based TS (UK) Limited found itself under growing pressure from rising energy costs and market uncertainty.
Part of the Italian Tontarelli Group, the £22m turnover company produces large-scale domestic plastic goods, such as kitchen storage, cleaning items and garden containers. It’s a large local employer with over 130 full-time staff members.
As the challenges piled up, the leadership team knew that continuing with business as usual was no longer sustainable. What followed was capital expenditure funding and consultancy support that led to a cost-effective digital transformation of its operations.
Standing still was not an option
“We were dealing with high energy costs, ageing equipment and operational inefficiencies,” explains Logistics Director, Lisa Finn. “We run 30 injection moulding machines and two grinders, many of which are older models that use excessive electricity and are prone to unplanned downtime. We knew we had to act if we were going to stay competitive and make the business fit for the future.”
Instead of replacing the machinery altogether, the company looked for a more affordable solution. “Retrofitting what we already had was clearly the better option for us,” says Lisa. “But making that happen wasn’t going to be straightforward and that’s why we got in touch with GM Business Growth Hub.”
Lisa began working with our Innovation Service, who helped shape the business case, put together a project concept, and produce a strong funding application. “We already had a clear vision, but we needed help turning it into a structured proposal that funders could back. I’m so happy there’s dedicated support and funding here in Greater Manchester for established companies like us.”
Innovation funding for leaner production
Thanks to this support, TS (UK) went on to secure more than £98,000 in innovation funding for a six-month partnership with an external specialist to test how far they could upgrade legacy machinery using retrofit solutions; the company contributed £12,000 of the total project cost.
The collaboration centred on three practical goals:
1. Internet of Things (IoT)-enabled monitoring – installing sensors to capture real-time data from moulding machines and grinders, including energy use, cycle times and output quality.
2. AI-driven predictive maintenance – developing models to spot early signs of mechanical issues, reduce breakdowns and plan maintenance more efficiently.
3. Advanced energy control units – adding new hardware that reduces power consumption by up to 30% and gives operators better real-time information and easier trouble-shooting.
Significant energy and productivity gains
This technical work has laid the foundations for a full rollout across TS (UK)’s machinery fleet, with initial energy and productivity gains forecast by January 2026 and full deployment across all machines targeted for July 2026.
Once fully implemented, the business expects:
- Up to 50% reduction in electricity use, equating to £500,000 in annual savings
- Significant reductions in downtime thanks to predictive maintenance
- 67% reduction in oil usage across modernised machines
- Faster cycle times and improved throughput
- Reduced manual handling and fewer bottlenecks on the production line
- Greater visibility and traceability across the whole process
The long-term commercial impact is equally important. With cheaper running costs, TS (UK) will be able to compete more effectively in high-volume, price-sensitive markets and strengthen relationships with major retail customers. Digitalisation also opens the door to new market segments that had previously been out of reach.
“You don’t need a ‘factory of the future’ to see the benefits of digital tech,” says Lisa. “We’re all about ‘winning ideas’ at TS (UK) and we’re proving that you get very modern capabilities without a huge budget if you have an innovative mindset and the right support.”
While the initial implementation is focused on the UK operation, the project has been designed from the outset as a scalable programme aligned to Tontarelli's international manufacturing footprint.
The digital retrofit approach, data architecture and operational learnings are being developed so they can be replicated across TS's overseas plants, enabling consistent performance improvements, energy reduction and productivity gains at a global level. This positions the project not as a standalone local initiative, but as a blueprint for wider group-wide deployment, ensuring the impact of the grant funding extends well beyond a single site and delivers long-term value across multiple international operations.
Lessons for manufacturers ready to modernise
Modern technology requires modern skills and TS (UK) plans to recruit two new technical roles to sustain the ongoing use of IoT systems and AI-driven maintenance tools, expertise that doesn’t currently exist within the business. Knowledge transfer from project partners will also help build long-term internal capability.
It’s a model that other manufacturers can follow, showing that you don’t have to replace everything with brand-new equipment to take advantage of Industry 4.0 technologies. With the right expertise, you can modernise what you have and deliver major productivity gains.
Contact our team today on 0161 359 3050 or at bgh@growthco.uk to find out how specialist support can help your business, whichever sector you’re in.
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